Outlander VCU - Rear inverter, Charger and BMS

[midway]

Done that
https://leafdriveblog.wordpress.com/202 ... -parallel/
https://leafdriveblog.wordpress.com/202 ... e-control/
https://leafdriveblog.wordpress.com/202 ... l-part-ii/

Same thing, only 3 chargers. By the way, please share your fuel cards.

[arber333]

Same thing, only 3 chargers. By the way, please share your fuel cards.

Fuel cards? You mean what i use for SOC calculation?

[midway]

Fuel cards? You mean what i use for SOC calculation?

No, I meant throttle maps

[arber333]

No, I meant throttle maps

Yes, i only use "sport" mode and "Normal" mode. To toggle between them i use the sport switch. I reversed the intention of sport mode so that it is the default state. Normal mode is used when weather conditions are not favourable and regen torque could cause slip. I dont use map2 at all.
With sport mode i use two regen states during pedal positions. This will give me "sort of" single pedal driving experience. Later with pedal position torque increases as you rearly need so much power, but when needed you need it quick. Value 24 is total overkill which i inserted to test if inverter would give more than 75kW or 200Nm. Sadly i wasnt able to get this even though i tried to increase HV voltage to 96S.

In the future i may smooth out the starting part of the curve so that i keep value at 3 for longer time. I noticed i need precise throttle movement only at really low speed such as congested traffic or at stop light.

Max speed with 10000rpm seems to be at 160km/h which is my calculation for 15in wheels.

Code: Select all

const int pedal_map_one[21][22] = {
    // Normal
    // map 1..
    /*250*/ {0, 3, 3, 4, 4, 8, 8, 8, 8, 8, 8, 9, 9, 10, 10, 10, 10, 12, 12, 14, 16},
    /*500*/ {0, 3, 3, 4, 4, 8, 8, 8, 8, 8, 8, 9, 9, 10, 10, 10, 10, 12, 12, 14, 16},
    /*625*/ {0, 3, 3, 4, 4, 8, 8, 8, 8, 8, 8, 9, 9, 10, 10, 10, 10, 12, 12, 14, 16},
    /*750*/ {0, 3, 3, 4, 4, 8, 8, 8, 8, 8, 8, 9, 9, 10, 10, 10, 10, 12, 12, 14, 16},
    /*1000*/ {0, 3, 3, 4, 4, 8, 8, 8, 8, 8, 8, 9, 9, 10, 10, 10, 10, 12, 12, 14, 16},
    /*1250*/ {0, 3, 3, 4, 4, 8, 8, 8, 8, 8, 8, 9, 9, 10, 10, 10, 10, 12, 12, 14, 16},
    /*1500*/ {0, 3, 3, 4, 4, 8, 8, 8, 8, 8, 8, 9, 9, 10, 10, 10, 10, 12, 12, 14, 16},
    /*2000*/ {0, 3, 3, 4, 4, 8, 8, 8, 8, 8, 8, 9, 9, 10, 10, 10, 10, 12, 12, 14, 14},
    /*2500*/ {0, 3, 3, 4, 4, 8, 8, 8, 8, 8, 8, 9, 9, 10, 10, 10, 10, 12, 12, 14, 14},
    /*3000*/ {0, 3, 3, 4, 4, 8, 8, 8, 8, 8, 8, 9, 9, 10, 10, 10, 10, 12, 12, 14, 14},
    /*3500*/ {0, 3, 3, 4, 4, 8, 8, 8, 8, 8, 8, 9, 9, 10, 10, 10, 10, 12, 12, 14, 14},
    /*4000*/ {0, 3, 3, 4, 4, 8, 8, 8, 8, 8, 8, 8, 9, 10, 10, 10, 10, 12, 12, 14, 14},
    /*4500*/ {0, 3, 3, 4, 4, 8, 8, 8, 8, 8, 8, 8, 8, 10, 10, 10, 10, 12, 12, 14, 14},
    /*5000*/ {0, 3, 3, 4, 5, 6, 8, 8, 8, 8, 8, 8, 8, 10, 10, 10, 10, 12, 12, 14, 14},
    /*5500*/ {0, 3, 3, 4, 5, 6, 8, 8, 8, 8, 8, 8, 8, 10, 10, 10, 10, 12, 12, 14, 14},
    /*6000*/ {0, 3, 3, 4, 5, 6, 8, 8, 8, 8, 8, 8, 8, 10, 10, 10, 10, 12, 12, 14, 14},
    /*6500*/ {0, 3, 3, 4, 5, 6, 8, 8, 8, 8, 8, 8, 8, 10, 10, 10, 10, 12, 12, 14, 14},
    /*7000*/ {0, 3, 3, 4, 5, 6, 8, 8, 8, 8, 8, 8, 8, 10, 10, 10, 10, 12, 12, 14, 14},
    /*7500*/ {0, 3, 3, 4, 5, 6, 8, 8, 8, 8, 8, 8, 8, 10, 10, 10, 10, 12, 12, 14, 14},
    /*8000*/ {0, 3, 3, 4, 5, 5, 8, 8, 8, 8, 8, 8, 8, 10, 10, 10, 10, 12, 12, 14, 14},
    /*10000*/ {0, 3, 3, 4, 5, 5, 8, 8, 8, 8, 8, 8, 8, 10, 10, 10, 10, 12, 12, 14, 14},
};

const int pedal_map_two[21][22] = {
    // Backup
    // map 2..
    /*250*/ {0, 0, 3, 4, 8, 10, 12, 8, 8, 8, 8, 9, 9, 10, 10, 10, 10, 12, 12, 14, 16},
    /*500*/ {-60, 0, 3, 4, 8, 10, 12, 8, 8, 8, 8, 9, 9, 10, 10, 10, 10, 12, 12, 14, 16},
    /*625*/ {-60, 0, 3, 4, 8, 12, 12, 8, 8, 8, 8, 9, 9, 10, 10, 10, 10, 12, 12, 14, 16},
    /*750*/ {-60, 0, 3, 4, 8, 12, 12, 8, 8, 8, 8, 9, 9, 10, 10, 10, 10, 12, 12, 14, 16},
    /*1000*/ {-90, 0, 3, 4, 8, 12, 12, 8, 8, 8, 8, 9, 9, 10, 10, 10, 10, 12, 12, 14, 16},
    /*1250*/ {-90, 0, 3, 4, 8, 12, 12, 8, 8, 8, 8, 9, 9, 10, 10, 10, 10, 12, 12, 14, 16},
    /*1500*/ {-110, 0, 3, 4, 8, 12, 12, 8, 8, 8, 8, 9, 9, 10, 10, 10, 10, 12, 12, 14, 16},
    /*2000*/ {-110, 0, 3, 4, 8, 12, 10, 8, 8, 8, 8, 9, 9, 10, 10, 10, 10, 12, 12, 14, 14},
    /*2500*/ {-130, 0, 3, 4, 8, 12, 10, 8, 8, 8, 8, 9, 9, 10, 10, 10, 10, 12, 12, 14, 14},
    /*3000*/ {-130, 0, 3, 4, 8, 12, 10, 8, 8, 8, 8, 9, 9, 10, 10, 10, 10, 12, 12, 14, 14},
    /*3500*/ {-150, 0, 3, 4, 8, 10, 10, 8, 8, 8, 8, 9, 9, 10, 10, 10, 10, 12, 12, 14, 14},
    /*4000*/ {-150, 0, 3, 4, 8, 10, 10, 8, 8, 8, 8, 8, 9, 10, 10, 10, 10, 12, 12, 14, 14},
    /*4500*/ {-150, 0, 3, 4, 6, 8, 8, 8, 8, 8, 8, 8, 8, 10, 10, 10, 10, 12, 12, 14, 14},
    /*5000*/ {-160, 0, 3, 4, 5, 6, 8, 8, 8, 8, 8, 8, 8, 10, 10, 10, 10, 12, 12, 12, 14},
    /*5500*/ {-160, 0, 3, 4, 5, 6, 8, 8, 8, 8, 8, 8, 8, 10, 10, 10, 10, 12, 12, 12, 12},
    /*6000*/ {-160, 0, 3, 4, 5, 6, 8, 8, 8, 8, 8, 8, 8, 10, 10, 10, 10, 12, 12, 12, 12},
    /*6500*/ {-160, 0, 3, 4, 5, 6, 8, 8, 8, 8, 8, 8, 8, 10, 10, 10, 10, 12, 12, 12, 12},
    /*7000*/ {-160, 0, 3, 4, 5, 6, 8, 8, 8, 8, 8, 8, 8, 10, 10, 10, 10, 12, 12, 12, 12},
    /*7500*/ {-160, 0, 3, 4, 5, 6, 8, 8, 8, 8, 8, 8, 8, 10, 10, 10, 10, 12, 12, 12, 12},
    /*8000*/ {-160, 0, 3, 4, 5, 5, 8, 8, 8, 8, 8, 8, 8, 10, 10, 10, 10, 12, 12, 12, 12},
    /*10000*/ {-160, 0, 3, 4, 5, 5, 8, 8, 8, 8, 8, 8, 8, 10, 10, 10, 10, 12, 12, 12, 12},
};

const int pedal_map_three[21][22] = {
    // Sport
    // map 3..
    /*250*/ {0, 0, 0, 3, 3, 4, 6, 6, 8, 8, 8, 10, 12, 12, 16, 16, 18, 18, 20, 24, 24},
    /*500*/ {-50, -30, 0, 3, 3, 4, 6, 6, 8, 8, 8, 10, 12, 12, 16, 16, 18, 18, 20, 24, 24},
    /*625*/ {-90, -60, 0, 3, 3, 4, 6, 6, 8, 8, 8, 10, 12, 12, 16, 16, 18, 18, 20, 24, 24},
    /*750*/ {-90, -60, 0, 3, 3, 4, 6, 6, 8, 8, 8, 10, 12, 12, 14, 16, 18, 18, 20, 24, 24},
    /*1000*/ {-120, -90, 0, 3, 3, 4, 6, 6, 8, 8, 8, 10, 12, 12, 14, 14, 16, 16, 18, 22, 24},
    /*1250*/ {-120, -90, 0, 3, 3, 4, 6, 6, 8, 8, 8, 10, 12, 12, 12, 14, 14, 16, 18, 22, 24},
    /*1500*/ {-160, -90, 0, 3, 3, 4, 6, 6, 8, 8, 8, 10, 12, 12, 12, 14, 14, 16, 18, 22, 24},
    /*2000*/ {-160, -90, 0, 3, 3, 4, 6, 6, 8, 8, 8, 10, 12, 12, 12, 14, 14, 16, 18, 22, 24},
    /*2500*/ {-180, -90, 0, 3, 3, 4, 6, 6, 8, 8, 8, 9, 10, 12, 12, 14, 14, 16, 18, 22, 24},
    /*3000*/ {-180, -90, 0, 3, 3, 4, 6, 6, 8, 8, 9, 9, 10, 12, 12, 12, 14, 16, 16, 18, 24},
    /*3500*/ {-180, -90, 0, 3, 3, 4, 6, 6, 8, 8, 9, 9, 9, 10, 12, 12, 14, 16, 16, 18, 24},
    /*4000*/ {-180, -90, 0, 3, 3, 4, 6, 6, 8, 8, 9, 9, 9, 10, 12, 12, 14, 14, 16, 18, 24},
    /*4500*/ {-230, -120, 0, 3, 3, 4, 6, 6, 8, 8, 9, 9, 9, 10, 12, 12, 14, 14, 14, 18, 24},
    /*5000*/ {-230, -120, 0, 3, 3, 4, 6, 6, 8, 8, 9, 9, 9, 10, 12, 12, 14, 14, 14, 18, 24},
    /*5500*/ {-230, -120, 0, 3, 3, 4, 6, 6, 8, 8, 9, 9, 9, 10, 12, 12, 14, 14, 14, 18, 24},
    /*6000*/ {-230, -120, 0, 3, 3, 4, 6, 6, 8, 8, 9, 9, 9, 10, 12, 12, 14, 14, 14, 18, 24},
    /*6500*/ {-230, -120, 0, 3, 3, 4, 6, 6, 8, 8, 9, 9, 9, 10, 12, 12, 12, 14, 14, 18, 24},
    /*7000*/ {-230, -120, 0, 3, 3, 4, 6, 6, 8, 8, 9, 9, 9, 10, 10, 12, 12, 12, 14, 18, 20},
    /*7500*/ {-260, -120, 0, 3, 3, 4, 6, 6, 8, 8, 8, 8, 8, 10, 10, 12, 12, 12, 14, 16, 18},
    /*8000*/ {-260, -120, 0, 3, 3, 4, 4, 6, 6, 8, 8, 8, 8, 10, 10, 10, 12, 12, 14, 16, 18},
    /*10000*/ {-260, -120, 0, 3, 3, 4, 4, 6, 6, 8, 8, 8, 8, 10, 10, 10, 10, 12, 14, 16, 18},
};

[midway]

Thank you, the tests were successful. I was especially pleased with the sport mode. Acceleration from 100 km/h in 9.6 seconds.

[arber333]

Thank you, the tests were successful. I was especially pleased with the sport mode. Acceleration from 100 km/h in 9.6 seconds.

I managed to get 8.7s at one time but i cant repeat this anymore. I dont know what i did.
Did you notice the slow start almost like a rubber band? I guess this takes at least 0.5s from you....

Also i must reseal all the moving parts of chassis. There is so much chatter in the undercarriage my teeth are rattling .

[marcexec]

It looks like Outlander inverter has a power limiter! Not amp limiter, but power limiter. When i had 84S battery inverter would let 230A go through which at 320V means 73kW. In the video i show steady acceleration and max current draw of 192A at 360V which makes about 70kW power from Outlander RWD motor. This means i will have to try to up the torque by software but the power will probably remain constant

Did you have a chance to test this again? Also, what year is your Outlander Rear Inverter? I.e. is it a 50 or 60kW unit originally?

[midway]

I managed to get 8.7s at one time but i cant repeat this anymore. I dont know what i did.
Did you notice the slow start almost like a rubber band? I guess this takes at least 0.5s from you....

Also i must reseal all the moving parts of chassis. There is so much chatter in the undercarriage my teeth are rattling .

I have a good response to the gas pedal, today I completed a trip of 160 km, the acceleration suits me. Only in sports mode did the limitation in the inverter work several times. Regarding the suspension, I had to change the arms and stabilizer struts, while the car was gasoline, I did not notice the suspension working.

[LRBen]

Did you notice the slow start almost like a rubber band? I guess this takes at least 0.5s from you..

I've noticed this with the outlander motor as well. Always felt like it had more torque once you were moving than off the line. Noticed this running it on my own VCU and also on zombieverter. So I would probably say it could be another inbuilt inverter limit.

[TRWIKI]

Thanks very much for sharing your work
aot93 and arber333

Would you still have any of the PCBs available?

I’m looking forward to testing all this out!

Good news is the teensy 4.1 seems to be back in general stock.

Bad news is the 3.x ones are still a way off by the looks of things, which makes the BMS side of things tricky.

If there is interest I can order do an order for some vcu boards from JLCpcb will take a few weeks on cheap shipping

I may have some unpopulated left. Which ones do you need? And where are you at?

Many thanks
C.

[midway]

Bad news is the 3.x ones are still a way off by the looks of things, which makes the BMS side of things tricky.

teensy 4.0 is a full replacement for teensy 3.6. The pin layout is completely the same, only the processor is more powerful

[aot93]

teensy 4.0 is a full replacement for teensy 3.6. The pin layout is completely the same, only the processor is more powerful

Sadly whilst the pins might be in the same place what they do is quite diffrent between the 3.x and the 4.x
Beside this some of the libraries used by simp are not compatible with the 4.x (try compiling with target board set to a 4.x to see which ones)

[aot93]

Would you still have any of the PCBs available?

I just checked there are a few left.
With outlander in Zombie now I won't be doing any more work on this, better to concentrate efforts on a common platform I think.